3D Printing Project Updates

 Left; This project was originally featured a considerable time ago and is based around using the 3D Printing PLA to produce a Catamaran.  This was first conceived in December 2017.  In this revised version the insides of the hulls have been deliberately left without infill to create air pockets to assist the boat to float. 

This is a considerable print looking at sixteen hours to print in its current form.  Details of the original print/project can be found here.  

Left: The most recent print on this site, the robot that is incorporating a pencil sharpener has had further development which has been driven and come from the student (ten years old) who designed the print.  While the teacher considered that the print had already been completed this student was adamant that it was not completed and was determined to include a second coloured print to contrast with the base colour and produce some basic features that would add depth to the print.   While these were only small additions to the print they produced a striking addition to the print.

Details of the original project/print can be found here. 

3D Printed Pencil Sharpener Exemplar

The design shown without the pencil sharpener inserted

Challenge: Students were given a variety of items that were common classroom items and challenged to produce a 3D Print that used the object in a way that complemented it.
Background: A number of the prints in this series have already been posted and detailed.   Some of them have already featured pencil sharpeners or magnets.    This was a student who wanted to push themselves with an extremely creative and detailed print.   They build the robot that is featured here in the design from 'scratch' using the parts of the Tinker cad main interface that would produce the various features.   They then developed the head of the robot to include an opening for a pencil to be inserted into an a second opening to house the pencil sharpener and also allow the waste from the pencil to exit out the mouth of the design.  Further printing was to include the facial features of the design to include eyes, which were printed separately with a secondary colour to make them stand out.   This student is a ten year old students who has consistently shown outstanding design ability and the idea of creatively making projects that both look appealing and also have a a balance between their size, creation and functionality.   

Above: Design showing pencil insert location in side of head.

Level of Difficulty: High.   This design took several versions to address issues relating to the placement of the pencil sharpener and the location of where it could successfully operate.   The design of the robot itself involved locating a number of features and making sure that they worked in unison with each other to create a design that looked detailed and also appealing.
Time frame: Six hours to complete the print at the standard default settings that we currently use and have done for the past four years or so - a 8mm nozzle with a 20% infill for the printing of regular PLA.    Given the general factors for the design and creation there was little room for adjustment. 
Size:   The print dimensions were 30mm across for the feet 50mm across for the body and arms.  A separate print was completed for the head.   This measured 50mm across and was 50mm high.  The dimensions of this required additional work to be completed. (See below).
What we would do differently: The dimensions of the print as specified above created an issue that the print became top heavy.  It is requiring an additional print to stabilize itself - while it works exceptionally well and looks commercial it was not built with perfect engineering hence the leaning that is taking place in some of the photograph the next step for the student is to design a stand that is suitable to allow the robot to remain standing up.

3D Printed Tractor Pencil Sharpener

Above: Design shown prior to removal of rafting

Challenge: To incorporate a pencil sharpener into a 3D Printed design.
Background: This challenge came as part of a group of objects supplied to students.   They were given a group of common objects from the classroom - pencil sharpeners and magnets.   There were several other groups of students operating in a process which involved a design/plan on paper and then was followed by a digital creation and feedback.  Other groups of students settled on a Pacman design (as featured on this blog here) and there are other designs to come.   These students opted for a tractor design with the design of the tractor coming from the main Tinkercad interface as the tractor was built from the basic shapes (starting with a rectangle for the base).   The students then added additional features to the tractor and produced the print shown.   Key to this was reviewing the print prior to printing to ensure that it was balanced, as in a review it was shown that the wheels needed to be adjusted.  This was two students who are ten years old first independent and significant 3D Printing project.   It should also be noted

Above: Design showing location of pencil sharpener.

that the students had minimal rafting on the design with the supportive PLA being restricted to the amount that was underneath the base of the tractor.   The students are going to review the print when it is completed and look to add additional details to the tractor.  These are going to be printed in relation to the size of the tractor that has been produced (see below).
Level of Difficulty: High - this design needs to work on two levels, the first aspect is the tractor design and creation.   The second aspect was the location of the pencil sharpener.  The students opted to have a inbuilt part of the tractor that was located at the front with an insert on the front right for the waste created by the pencil sharpener.  Both thsee aspects needed to work in unison for the print to be successful.  The pencil sharpener was a mass produced inexpensive plastic one which allowed the possibility of it being super glued into place or being slightly adapted to fit a specific place with regards to the print.

Time frame: Sixteen hours - given the scope and size of the print this is the minimum that would be required to make this print both robust and successful.
Size: The print was 140mm long and 130mm high including the wheels.   The base of the tractor was 40mm across.  The location hollow for the pencil sharpen was essentially a 30mm by 30mm insert into the base of the tractor. 
What we would do differently: Very little - two students have worked on a design for a considerable amount of time to rework, revise and produce something significant.

3D Printing: Incorperating a common object

Above: Pac-man finished design with sharpener in place

Challenge: For students to design something original that would use another common object - pencil sharpener.
Background: In this example the students were given a choice of objects and asked to design a 3D Print that would work in conjunction with the object.   The items were standard pencil sharpeners and magnets.   Students were then able to use technology to search for inspiration online and look at examples that could be found on various sites.   From there the students were tasked with deconstructing the objects and coming up with their own versions which they had adapted to suit the objects that they were supplied with.   The first pair of students who created an idea quickly choose to go with a pencil sharpener as the object and create a pac-man base for the object to be housed in.   The students are only ten years old so the creation of a pac-man

Above: Design shown from other side.

theme for the item came as a result of being aware of the shape rather than fans of the game (which came out in 1980!).   The challenge for the students was having the two items work together in a practical way and in particular the insert for the pencil relative to the blade for the pencil sharpener.
Level of Difficulty: Medium - as always combining two different aspects of a print or a print and an object can be complicated and difficult for the students to sometimes master, as has been the case for this.   A further unexpected aspect to this print was the shavings from the pencil when the sharpener is used this needs to be put into the rubbish bin - the students hadn't anticipated the sharpening and where that would come as a result of the pencil sharpener being used. 
Timeframe: Five hours.  The print is was relative to the size of the project and the pencil sharpener. 
Size: The design measured 80mm across and was 80mm high.   The design was relative to the shape of the pencil sharpener.  The students had a free choice with what they choose and opted for a double pencil sharpener.  If you look at the photos you can clearly see a single pencil insert.
What we would do differently: This challenged the students who attempted it on the basis of having the relationship between the print and the object.   The students attempted to complete a complex design to work and are constantly reviewing the project.